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Koolaire KD0500A - Service Manual

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Part Number 000012545 4/14
Ice Machines
Installation and Maintenance Manual

Table of Contents

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Summary

General Information and Safety

Installation and Operation Safety Warnings

Crucial safety guidelines for preventing personal injury and ensuring proper appliance use.

Electrical Appliance Safety

Essential precautions when using electrical appliances, including grounding and cord safety.

Model Identification and Bin Installation

Covered Ice Machine Models

Lists the self-contained air-cooled, water-cooled, and remote ice machine models covered by the manual.

Ice Deflector and Bin Mounting

Specifies deflector requirements and provides bin installation guidelines.

Installation Location and Clearances

Ice Machine Location Criteria

Criteria for selecting a suitable location, considering air quality, temperature, and obstructions.

Required Clearances Chart

Table detailing required clearances for different ice machine models and configurations.

Temperature Protection Advice

Warning about protecting the ice machine from freezing temperatures to avoid warranty voidance.

Heat Rejection and Bin Preparation

Heat of Rejection Data

Data on heat rejection for different ice machine models, useful for HVAC sizing.

Bin Leveling and Drain Plug Removal

Step-by-step guide to preparing the ice storage bin for machine installation.

Air Baffle Installation

Instructions for installing the air baffle to prevent condenser air recirculation.

Electrical Service Requirements

Minimum Circuit Ampacity Calculation

Guidance on selecting the correct wire size for the electrical supply.

Power Supply and Grounding

Details on power supply, grounding, voltage variation, and dedicated circuits.

GFCI Protection Recommendations

Information and recommendations regarding GFCI protection for the ice machine.

Power Cord Specifications

Specifications for power cords, including gauge and length, based on breaker size.

Electrical Specifications Chart

Water Supply and Drain Requirements

Water Supply and Treatment

Recommendations for water quality, treatment, and connection to potable sources.

Water Inlet Line Installation

Guidelines for installing water inlet lines, including filter systems and pressure considerations.

Drain Line Installation Guidelines

Instructions for proper drain line installation to prevent backflow and ensure adequate drainage.

Water;Drain Line Sizing and Cooling Towers

Water;Drain Line Sizing Table

Detailed table for water and drain line fittings, sizes, and pressure specifications.

Water-Cooled Condenser Cooling Towers

Specific considerations for installing water-cooled models with cooling towers.

Remote Condenser Installation Details

Refrigerant Charge for Remote Units

Information on factory refrigerant charge and how to add refrigerant for longer line sets.

Remote Condenser Ambient Temperature Range

Specifies the acceptable ambient temperature range for remote condensers.

Certified Technician Requirement

Emphasizes the need for certified technicians for refrigerant handling.

Remote Condenser Installation General Guidelines

Condenser Mounting and Airflow

Guidelines for horizontally mounting condensers and ensuring adequate airflow clearance.

Interconnecting Wiring

Describes how to connect the remote condenser to the ice machine head section.

Refrigerant Line Routing Best Practices

Best practices for routing refrigerant lines to ensure performance and accessibility.

Remote Condenser Line Set Distance Calculations

Line Set Distance Limits

Details maximum lengths, rises, drops, and total calculated distances for line sets.

Calculating Line Set Distance

Provides formulas and examples for calculating acceptable line set distances.

Line Set Connections and Pressure Testing

Line Set Routing and Kink Prevention

Instructions to route line sets to avoid traps and kinks.

Line Set Brazing and Protection

Steps for cutting, purging, and brazing line sets, with precautions for shutoff valves.

System Pressure Testing and Evacuation

Procedures for pressure testing and evacuation to ensure system integrity.

Opening Line Set Valves

Guidance on opening line set valves and checking for leaks.

Installation Completion Checklist

Pre-Operation Checks for Remote Models

Specific checks for remote condenser installations after start-up.

Final Steps Before Machine Operation

Final steps and responsibilities before operating the newly installed ice machine.

Ice Making Operation Sequence

Ice Production Cycle Stages

Describes the step-by-step process of ice production from water purge to harvest.

Control Board Timing Functions

Details the non-adjustable timers on the control board that govern ice making cycles.

Understanding Safety Limit Features

Explains the built-in safety limits that stop the machine to prevent component failure.

Operational Checks and Adjustments

Performing Operational Checks

Guidelines for performing operational checks after initial setup or maintenance.

Adjusting Ice Thickness

Procedure for inspecting and adjusting ice thickness for optimal cube formation.

Ice Machine Cleaning and Sanitizing

Cleaning Responsibilities and Schedule

Outlines the user's responsibility for maintaining the ice machine's cleanliness.

Full Cleaning and Sanitizing Procedure

Step-by-step instructions for thorough cleaning and sanitizing every six months.

Preventative Cleaning Procedure

Describes a procedure for cleaning the water flow path between major sanitizing cycles.

Exterior Surface Cleaning

Guidance on cleaning the exterior surfaces of the ice machine.

Cleaning and Sanitizing Procedure Details

Cleaner Solution Preparation and Use

Instructions for mixing and applying the ice machine cleaner solution.

Sanitizer Solution Preparation and Use

Steps for mixing and applying the ice machine sanitizer solution.

Parts Removal for Cleaning;Sanitizing

Water Curtain Removal Steps

Instructions for removing the water curtain for cleaning.

Water Trough Removal Steps

Steps for detaching and removing the water trough.

Float Switch Removal Steps

Guidance on removing the float switches for cleaning.

Water Distribution Tube Removal

Instructions for disassembling and removing the water distribution tube.

Preventative Maintenance and Component Cleaning

Preventative Cleaning Procedure Steps

Steps for performing preventative cleaning of the water flow path.

Front Door Removal Procedure

Instructions for removing the ice machine's front door.

Condenser Filter Cleaning

Guidance on cleaning the washable filter for self-contained ice machines.

Condenser Cleaning Instructions

Procedures and warnings for cleaning the condenser for optimal performance.

Removal from Service and Winterization

General Ice Machine Winterization

Steps for properly preparing the ice machine for storage or winterization.

Water-Cooled Unit Winterization

Specific winterization procedures for water-cooled models.

Troubleshooting Checklist

Pre-Operation Checks for Remote Models

Specific checks for remote condenser installations after start-up.

Restart Procedure Before Service Call

Procedure to restart the machine before contacting service for safety limit issues.

Ice Quality and Capacity Troubleshooting

Ice Formation and Production Issues

Addresses problems related to ice cube quality, shape, and overall ice production capacity.

Safety Limit Restart Protocol

Details the function of safety limits and how to attempt a restart before calling service.

Commercial Ice Machine Warranty Details

Warranty Registration and Contact Info

Instructions for registering the warranty and company contact details.

Residential Ice Machine Warranty Information

Warranty Exclusions and Limitations

Lists exclusions from the limited warranty coverage.

Obtaining Warranty Service

Provides instructions and contact information for obtaining warranty service.

Ice Storage Bin Warranty Terms

Bin Warranty Exclusions

Lists specific exclusions from the ice storage bin warranty.

Ice Storage Bin Claim Procedure

Steps for customers to follow when making a warranty claim.

Residential Ice Machine Warranty (Continued)

Warranty Coverage Exclusions

Further details on exclusions from the residential ice machine warranty.

State Law and Warranty Rights

Information on how state laws may affect warranty rights.

Warranty Registration Process

Instructions for completing and submitting the warranty registration card.

Ice Storage Bin Warranty Limitations

Liability Limitations for Bins

Outlines limitations on the company's liability regarding ice storage bins.

Bin Warranty Remedies

Describes the remedies available for warranty breaches concerning ice storage bins.

Governing Law for Bin Warranty

Specifies the governing law for the limited warranty.

Koolaire KD0500A Specifications

General IconGeneral
Production Capacity500 lbs per day
Ice TypeFull Cube
Power Supply115/60/1
Daily Ice Production500 lbs
Condenser TypeAir-Cooled
Ice Production500 lbs per day
RefrigerantR404A
TypeIce Maker
Weight180 lb
Width30 inches
Ice Storage CapacityNot Applicable (Modular)

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